Winkhaus is a fifth-generation family business and one of Germany's leading manufacturers of window fittings, door locks, and access systems. Window technology is produced at the headquarters in Telgte, North Rhine-Westphalia. "Depending on the equipment, our windows have around nine assemblies and about 100 individual parts," says Stephan Kortenbrede, head of production equipment construction. His team of over 50 people manufactures all the tools and spare parts used for cutting, punching, or forming the fittings.
The equipment manufacturing department sees itself as an internal service provider for production and is familiar with its challenges: "We process different materials that vary greatly in terms of thickness and quality. But one thing always remains the same: we have to ensure both efficiency and product accuracy in production, because our window technology is certified according to various criteria," explains Kortenbrede.
Challenges: Higher weight and burglary protection
It's not just about the durability of the individual components. There are two particular challenges in window construction: On the one hand, windows are becoming heavier, both due to their design – keyword: multiple glazing – and their increasing size. Architects and builders want as much light as possible in the rooms. For example, a glazed patio door can weigh up to 150 kg.
On the other hand, there is also the issue of security. Windows must meet current requirements in terms of burglary protection. Kortenbrede cites mushroom heads as an example: these are special locking bolts that hook firmly into security strike plates in the frame when the window is closed. Or hooks made of high-strength materials that can be used in door systems. "The development of our products is very complex and intensive because they are all certified. This means that we have to comply with many specifications and guarantee correspondingly high quality," says Kortenbrede.
Durable coatings for tools
Winkhaus's equipment manufacturing division therefore relies on coatings from Oerlikon Balzers. For example, punches and cutting dies are coated with the TiAlN coating Balinit Futura Nano. Arc PVD is used to create a violet-gray coating with a coating hardnessHIT of 33 (±3) GPa. According to the manufacturer, Balinit Futura Nano offers an optimized balance between hardness and compressive stress. Its hardness and composition make it suitable for heavily loaded precision components as well as HSS and carbide tools. It allows higher cutting speeds and improves surface quality. Based on its practical experience, the coating supplier specifies a maximum application temperature of 900 °C, with a process temperature of 500 °C achievable.
Press stamps and dies are coated with Balinit Alcrona Evo, the further development of the Balinit Alcrona Pro coating, in the Winkhaus halls. According to Oerlikon Balzers, it offers better wear resistance than its predecessor, which is reflected in the extended service life. The AlCrN-based Arc PVD coating has a layer hardness ofHIT 44 GPa (±4) and an internal stress of -3.5 GPa (±1). Based on its practical experience, the manufacturer specifies a maximum application temperature of 1,100 °C. The process temperature should be below 500 °C.
Winkhaus has been using the advanced coatings with
Winkhaus has been using Balinit Alcrona Evo for several months now and is very satisfied with it. What prompted him to make this change? Kortenbrede smiles a little and then says: "When Oerlikon Balzers further develops its coatings, we always follow suit. We trust in their expertise and are therefore always at the cutting edge of technology."
He has had good experiences with this approach: "We want defect-free tools that are easier to process and ensure smooth operation of the machines. Longer service life is particularly important for items that are produced around the clock. And finally, it's all about surface quality, for example in the case of countersinks, which we use to manufacture door locking hooks. We still galvanize our components ourselves, so a surface that is as smooth and burr-free as possible is a prerequisite for meeting our quality standards in electroplating as well."
A relationship of trust has developed over the years
Winkhaus and Oerlikon Balzers have been working together for many years. A close supplier-customer relationship is also part of the hardware manufacturer's corporate philosophy. This involves more than just punctual order fulfillment: "It is important to us that our suppliers understand what is important for our products. We want them to be familiar with our processes and know what we need. This not only makes day-to-day business run more smoothly, but also enables us to deal with exceptional situations better together," says Kortenbrede.
A few years ago, for example, order processing was redesigned jointly to optimize the process in both companies. "Oerlikon Balzers makes us feel that, as a customer, we are a valued partner on an equal footing. For us, good availability, delivery times, and the fact that we always have a contact person we can turn to are crucial – as is the fact that we work together to find new solutions," says Kortenbrede with satisfaction.